Electrical coil assemblies



I P 1967 J. DOUGALL 3,343,113

ELECTRICAL COIL ASSEMBLIES Filed July 26, 1965 United States Patent3,343,113 ELECTRICAL COIL ASSEMBLIES John Dougall, Birmingham, England,assignor to Joseph Lucas (Industries) Limited, Birmingham, England FiledJuly 26, 1965, Ser. No. 474,692 Claims priority, application GreatBritain, Aug. 7, 1964, 32,17 3/ 64 1 Claim. (Cl. 336-192) This inventionrelates to electrical coil assemblies of the kind comprising a generallycylindrical body of electrically insulating material, upon which iswound a length of electrically conducting wire, the ends of which areconnected to terminal pieces.

The object of the invention is to provide a coil assembly of the kindspecified, in a convenient form.

According to the present invention, a coil assembly of the kindspecified is characterised in that the terminal pieces are of plate-likeform and are secured to lugs extending from the body and formedintegrally therewith, these lugs being formed with respective aperturesfor the reception of a tool or a part thereof for making an electricalconnection between. the wire end and terminal pieces.

The body may be formed with a generally radially extending slot in oneof a pair of flanges bounding the portion of the body on which the wireis wound, the slot extending across substantially the whole of theradial width of the coil of wire.

A specific example of the invention will now be described by way ofexample with reference to the accompanying drawings in which:

FIGURE 1 is a side elevation view of a coil assembly constructed inaccordance with the invention and FIGURE 2 is a plan view of theassembly.

In this example there is provided an electrical coil assembly comprisinga body formed from an electrically insulating material such as asynthetic resinous material. The body is formed by an injection mouldingprocess and is of generally hollow cylindrical form with two outwardlyextending annular flanges at opposite ends respectively. One of theannular flanges has formed integrally therewith a pair of generallyradially outwardly extending apertured lugs 11, 12. Each of the lugs 11,12 has a first aperture 13 for reception of a tool and a second aperture14 for reception of a fastening element for an electrical lead.

Each lug 11 or 12 is also formed with a pair of integral projections 16arranged to engage in holes in an electrically conducting aperturedplate-like terminal piece 17 or 18 assembled in face-to-facerelationship with the lug 11 or 12. To secure the terminal pieces inplace on the respective lugs, the ends of the projections 16, arepressed to form heads.

The terminal pieces 17, 18 extend over the apertures 13 in the lugs 11,12 respectively, and opposite ends of 3,343,113 Patented Sept. 19, 1967ice a length of wire 19 coiled on the body 10 between the annularflanges, are connected to the terminal pieces 17, 18 respectively bymeans of respective bent over tabs 20, formed on the terminal pieces 17,18, the wire ends being secured in place by resistance welding. One ofthe portions of a tool used in carrying out this resistance weldingprocess is passed through the aperture 13 in the appropriate lug. Eachtab 20 has a V-shaped slot for the wire, to hold this in place prior towelding, the respective slots being indicated by numerals 24, 25.

The apertures 14 in the lugs 11, 12 are aligned with those in theterminal pieces respectively, the fastening elements thus makingelectrical connection with the terminal pieces.

The body 10 has a pair of integral projections 21 which are arranged toengage in a support bracket for the assembly the ends of thoseprojections 21 being pressed to form heads. In the annular flange of thebody 10 on which the lugs are formed and nearer one of the lugs than theother is a'slot 22 extending generally radially of the body. This slot22 extends over substantially the whole radial width of the flange andis provided to facilitate retrieval of the end of the wire 19 at theinside of the coil, when this end of the wire is to be connected to aterminal piece. A portion of the flange on the side on which the coil iswound is of reduced thickness as indicated by the dotted line 23, thusdefining a cavity for the end of the wire.

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent is:

An electrical coil assembly comprising a generally cylindrical body ofelectrically insulating material, the body having integral flanges atthe ends thereof respectively, a pair of integral lugs extending fromthe body, a length of electrically conducting wire wound on the body, apair of plate-like terminal pieces mounted upon the lugs respectively,means for connecting the ends of the wire onto the terminal pieces, andthe lugs being formed with respective apertures for reception of a toolwhereby said means for connecting the wire to the terminal pieces can bemanipulated.

References Cited UNITED STATES PATENTS 1,100,178 6/1914 Forsberg 336-192X 1,360,752 11/1920 Johannesen 336-192 X 2,453,158 1l/1948 Price 336-1922,828,393 3/ 1958 Wingard.

3,117,294 1/1964 Muszynski 336-192 3,142,030 7/1964 Lenox 336-192 X3,230,489 1/1966 Weyrich 336-192 DARRELL L. CLAY, Primary Examiner.

L. H. MYERS, Examiner.

E. A. GOLDBERG, Assistant Examiner.

